Felt carpet or rug and method of making the same



April 6, 1938. R. H. JOHNSON 2,115,581

' FELT CARPET OR RUG AND METHOD OF MAKING THE SAME Filed July 5, 1935 INYENTOR Q ad? TM ATTORNEY5 Patented he. 26,

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Iherinnid m. .iiohn. i dorsiewood, hi i1, nesirrnor to dnciericnn heir it ii eit Gomnnnr, hit, it cor rorntion oi heinwere inniicntion ci'riiir it, with herini Noqthtidii i diininin.

The invention reintee to ieit cerneto or rai s end to o method oi rnoirinn the "Where carpets or runs ere rnnde hr the neediine or enriching method of ieitohie hhree the hody oi the ninterini in t udte eieetic end ordinnrii'y door.

not hoid its shrine es weii he the denni woven" ten-- the cnroets. The rndin ohiect oi the present invention is to provide at method oi nieidn cernete or rues which wiii hoid their o More nniticuieriy decor-dine to the nreeent in" vention the felt hot it necdied to it reiniorcine i'ehric, such he hnrion, end then needied to e. second ioyer or reiniorcnn iohric disnoeed editieentthe iiret ierer with an inner or needied iihreo therehetween and forming with the hottoin iehrie on nheorntive eree i'or e. einine end hinder which iinnir nnchors. the three at their time ond ives hodgv to the innteriei, the'needied hortion hetween the iohrics oieo nrerentinr reed'y nenetro- 2 tion oi thesieinennd hindine coninoeition herond "the first inhric inner end ienvinn the main hodr oi ieitnhie iihres in n condition heet ouited tor producine reidtivein henrr non or ratio which eives the product the nnncnrnnee rind ieei oi woven cer et. iiiterthe .nonninir onerdtion n third hirer oi iehric ie cemented or edheeireir secured tothe nrevionrir needied ondtreotcd iifitt terioi to iorni the dniehed hrodnct whose ton suriece hes the ennenrnnce-nnd i'eei orworen oer-net end whose hodr nortion" is reidtiveir ihred oeoinet shrininne or. ,ttretcn rind wiii hoid its shone indeflniteir'.

The invention iurther consiete in the eeverni ieotures hereinniter set iorth end more portioniorir donned hrcininis. hi the conciusion hereof.

in the drewine:

tie, it is n View showine the oi ieitehie :iihres positioned on o idiotic hnee nrennrntory to the hint neediine onerotion;

w the. h is n. view oi the rnoterioie ohown in i eiter the first neediine' onerntion;

hie. d is o. view showinn the eten oi nene at second iehric hose to the here of the nreviourir needied materiel;

5, hie. d is e. view showinn the innteriei etter treatment with e. sizing end hinder;

tie. it is it view ehowin the rnoteriei eiter the napping operotion;

l te. ii is it view showing the constricted te-= riot niter the new or piie hoe heen eheered odd o. reinforcing iehric hose hoe heen nnniied to the previously needied and treated moterioi.

According to the invention eny suitohie enimni or vegetebie fibres or mirturee of such hhres are formed in the usuei manner in o hart t of enr desired thicirneee which it ioid over or denoeited on e reinforcing iehrichnoe ii, ouch he hurien oi one enitehie neeeh, these nert-e heinn shown. in

Ii. in thincondition the nioteriei is ted into n neediinn iooni or nunchine rnnchine, with the ,5 needles iii detains; item the too side, end hr this I onerntion idhree oi the ere interiocired with eech other end with the iehric hose ehown in E. By this o eretion e euhetentioi pronor tion oi the ieitehie hhres ore erreneed to entend to enhstentieiiy norrnei to thesnrieice oi the top inner end eonie oi the iihres, indicnted hr the nurnerei it, protect thronhh the iohricheoe.

Ti'itiii'hh-ftei', e. recond inhric inyer iii er hnrie ,or other enitehie mnteriei is positioned heneeth 15 the revioneir needied nioterini end the ports thns orrnneed ere ted into e. neediine iooni or nncmne niochine, with the neediee iii octind irorn the top side, end h this onerotion iihres oi the hnt ere inrther interiocired with ench other one some oi the i'ihres ere interioched with one or hoth oi the inhric hnsce or intern end it he shown in the. Li. hr thie operation the ieithhie iihres ere tnrther nrrenzred to extend tuhotnntioiir normei to the enrioce' oi the top inner end some oi the hhree, indicnted hr the nurnernl it, project through the tower iehric inner it; it is oiso to he noted thot eorne oi the iihres ii i'orin o idhrous inner or oreo. it hetween the idhric inrers end iii.

' 3d Thereeiter; the hose nortion or hottoni eide oi the ninteriei istreeted to o. oininn end hinder which nenetretes to the iiret iohric 'ierer end in this connection the hhrous hirer or tree iii is or nroteriei neeietence in chechine the nenev tintion oi the eieine end hinder nieterieiir heyond seid iiret iorer es shown in die. i. ihie hinder end shrine is deeienoted hr the nerni it end is oriented to give the i'eit hodr iiie do thnt it many he reediit roiled end unroiied end when nnroiied wiii nieinteiin itseli in o. net condition on the door end wiii not cnri no nt the edges. "the rareierred hinder is e mixture oi o euitehie euni end n thin rnhher eoiution. "the is preierehiy n tepioco. eulnr end the rubber o. nnturei or ertidcini' t5 dispersion oi ruhher in on o ueoue ii nid. A hien'ient or dye ior coiorine the product they eioo he edded to this mixture. The time rnnr contoin nhout one port euro to about two end one-heii ports oi the rnhher dispersion, end it may in the to proportion oi one port soiid rubber to tour ports of wetter he oppiied to the felt body by twine nick-up or shine roiis. it of course, he understood that the rubber concentration thei very under diderent conditions and he e r-eater 55 or less than that specificallymentioned, for example, this concentration may vary from 10% to 30% of the mixture.

To secure greater penetration of the binder, a. wetting agent, such as sulfonated oils, saponin, sodium sulfanilate, may be mixed with the rubber dispersion. Where a vulcanized product is desired, the binder may have a suitable vulcani'zing agent added to it and also a suitable accelerator if vulcanizing at low temperatures is desired.

The body thus formed is next subjected on the uncoated side and on the side from which the needles entered to the action of a suitable napping machine which acts to raise'a heavy or thick nap or pile formed by upwardly projecting portions ll of some of the fibres, as shown in Fig. 5, which is preferably trimmed to a substantially uniform thickness or height, as shown in Fig. 6, and imparts to the punched product the appearance'and feel of woven carpet. The interlocking ,of the fibres provides a good foundation for anchoring the napped fibres, and these napped fibres for the most part extend substantially normal to the top of the fabric body. The feltable fibres are preferably animal hair, but other fibres such as hemp, jute, or other vegetable fibres might be used or mixed with the animal hair if desired.

The material thus prepared is preferably then subjected to a suitable stretching operation more severe than it will in most cases ever get in service and to this pre-stretched material a base layer It of suitable material is secured by suitable adhesive, as for example rubber cement. This base layer It may be a pre-shrunk and stretched burlap either with or without a sizing. The finished product is shown in Fig. 6.

I desire it to be understood that this invention is not to be limited to any particular form or series of steps except in so far as such limitations are included in the claims.

What I claim as my invention is:

l. The stepsJn the method of making carpets or rugs of feltable fibres which comprises needling a fibrous bat to a woven fabric base, needling this previously needled material directly to another woven fabric base with the base fabrics adjacent each other and projected fibres from both needling operations between them, applying a sizing and binder to the needled material from the base fabric side and to a depth not materially greater than the first base fabric, and napping the top surface of the needled fibres.

2. The method of making carpets or rugs of feltable fibres which comprises needling a fibrous bat to a woven fabric base, needling this pre-. viously needled material directly to another woven fabric base with the base fabrics adjacent each other and projected fibres from both needling operations between them, applying a sizing and binder to the needled material from the base fabric side and to a depth not materially greater than the first base fabric, napping the top surface of the needled fibres, and adhesively securing a shape-maintaining base layer to the bindertreated side of said needled and napped material.

3. Themethod of making carpets or rugs of feltable fibres which comprises needling a fibrous bat to a woven fabric base, needling this previously needled material to another fabric base with the base fabrics adjacent each other and projected fibres from both needling operations between them, applying a sizing and binder to the needled material from the base fabric side and to a depth not materially greater than the first base fabric, napping the top surface of the needled fibres, stretching the needled and napped material, and adheslvely securing a base layer of pre-stretched material to the binder-treated side of said needled and napped material.

4. A pile fabric which comprises a plurality of superimposed woven base fabric layers needled directly together, a bat of fibrous material needled to said base layers with needled fibers from said fibrous material enmeshed between said layers, a binder coating on the base side of said fabric penetrating to the upper of the fabric layers, the fibers between said base layers acting to check penetration of said coating beyond said fabric layers, the uncoated. side having a relatively large proportion of surface fibers projecting therefrom to form a thick pile or nap.

5. A pile fabric which comprises a plurality of superimposed woven base fabric layers needled directly together, a bat of fibrous material needled to said base layers with the needled fibers from said fibrous material enmeshed between said layers, a binder coating on said fabric layers penetrating to the upper of the fabric layers, the fibers between said base layers acting to check penetration'of said coating beyond said fabric layers, the uncoated side having a relatively large proportion of surface fibers projecting therefrom to form a thick pile or nap, and a base layer secured to the coated side of said superimposed base fabric layers.

Q, A pile fabric which comprises a plurality of superimposed woven base fabric layers needled directly together, a bat of fibrous material needled to said base layers with the needled fibers from said fibrous material enmeshed between said layers, a binder coating on said fabric layers penetrating to the upper of the fabric layers, the fibers between said base layers acting to check penetration of said coating beyond said fabric layers, the uncoated side having a relatively large proportion of surface fibers projecting therefrom to form a thick pile or nap, and a woven base layer secured to the coated side 'of said superimposed base fabric layers.

REGINALD H. JOHNSON.

of the above numbered patent requiring correction asiifollows: Page 1, first Letters Patent should be read with'these corrections therein that the same CERTIFICATE OF CORRECTION.

Patent No. 2,115,581. April 26, 1958.

' REGIME H.- JOHNSON.

It is hereby certified that error appears in the printed specification column, line 15, for "reinforcng" read-reinforcing; page 2, second column line 10, claim}, before the word "fabric" insert woven; and that the said may conform to the record of-the' case in the Patent Office.

' Signed and sealed this 11 th day of June, A. D. 1958.

Henry Van Arsdale, '(Seal) Acting Comissioner of Patents. 

